Pile wire loom and method of weaving



July 20, 1937. w. A; RI CE ET AL %4 FILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1933' 16 Sheets-$heet l k 7 (D X\ N 0 on N N lNVENTORs 4 Walter A-RLCQ, and

w. A. RICE ET AL PILE WIRE LOOM AND METHOD OF WEAYING July 20, 193 7.

1e Shets-Sheet 2 Filed April 1, 1953 July 20, 1937. w. A. RICE ET AL FILE WIRE LOOM AND METHOD OF WEAVING 1e Sheets-Sheet 3 Filed April 1, 1955 ORNEYJ July 20, 1937. w. A. RICE ET AL FILE WIRE LOOM AND METHOD OF WEAVING Filed April '1, 19:53

ow o 1 l6 Sheets-Sheet 4 INVENTQRS waiter H.-QL&. and.

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- ATTORNY6 July 20, 1937.

w. A; RlcE ET AL PILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1953 16 Sheets-Sheet 6 Asv ORNEYS y 7- w. A. RICE ET AL 2 ,087,449

FILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1933 16 Sheets-Sheet '7 W A 8W AITORNEKJ ly 20,1931. w. A. RlcE' ET AL 2,087,449

FILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1935 16 Sheets-Sheet s 117 15 7 9 1 1 NT Rs [1711 1 169 UILNLVEGVOPLEE'GO, and. 1Z2 B'Y FrqvxK emin.

July 20, 1937.

W. A. RICE ET AL FILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1953 iso -166- 1 15 ms L i i 1 v m5 162 mi. "''1 r 165 162 164- 16 Sheets-Sheet 9 INVENTORS Walter A. 'P.\oe aaA' A ATTORNEYS W. A. RICE ET AL FILE WIRE LOOM AND METHOD OF WEAVING July 20, 1937.

Filed April 1', 1935 INVENTORS WaL'ter A.Rice., a d.

'FvanK (1 shinn- July 20, 1937. w. A. RICE ET AL 2,087,449

PILE WIRE LOOM AND METHOD OF WEAVING v I Filed April 1, 1933 16 Sheets-Sheet l4 75- 76 14, 1 FIG. 270..-

. INVENTORS Q/ FIG. I

July 20, 1937.

W. A. RlgiE ET AL FILE WIRE LOOM AND METHOD OF WEAVING Filed April 1, 1933 16 Sheets-Sheet 15 FIG. 2

INVENTORS waLter Ricgqnal BY Frank 6.6hinn- W Asm- TH ATTORNEYS UNHTED STATES OFFICE] PILE WIRE LOOM AND LIETHOD OF WEAVING Walter A. Rice, Yonkers, and Frank G. Shinn, Bronxville, N. Y.

Application April 1, 1933, Serial No. 663,964

37 Claims. (Cl. 139-37) Our invention relates to certain new and useloops form the boundaries of and are parts of ful pile fabric looms, in which we weave pile adjoining knots, and ultimately cutting the'tuft fabric having knotted tufts. V yarn loops by movement of the pile wires or not vThe principal purpose of our invention is to cutting the loops as desired. 'form blotted tufts around the warp and prefer- A further purpose is to pass the tuft yarns of ably also the weft threads of a. fabric from a cona pile wire loom through needles by which they tinuously supply of yarn, cutting the tufts or not are subsequently controlled, and to manipulate as desired. the individual tuft yarns by the needles both lat- A further purpose is to use continuous tuft erally and vertically to pass the pile yarn around yarns in a pile wire loom to form knots having the crossing point of crossed warp threads longian eye and a loop each, about the warp threads tudinally of the loom, as a preliminary to formalone or about warp and weft threads in a fabric ing knots, using pile wires as adjuncts tohold as desired. the loop portions of the knots between succeed- A further purpose is to effect the crossing of ing operations. 15 warp threads in a pile wire loom by a manipulat- A further purpose is to weave patterned knoting device for shifting continuous tuft yarn. ted rugs, carpets or other knotted pile fabrics A further purpose is concurrently to divert the from a continuous yarn supply or source on-which warp threads laterally in a pile wire loom to 'yarn supply. or source the pattern appears in cross them, and to manipulate the tuft yarn'in an elongated form but when :woven produces a the loom so as to knot it about the crossed warp predetermined design or pattern inthe'fabric. 20 threads, or the warp and weft threads as pre- A further purpose is to use a positive lifting ferred, preferably performing thecrossing of the and lowering pile yarn carrier to form. a shed warp threads and manipulation of the tuft yarn for a. pile wire, said yarn carrier also being used y es t o h-- W o ey s the f: y to cross warp threads during the weaving of the P knotted pile fabric. 25

A further purpose is to manipulate continuous A further purpose is to make the same loom Pi y in a 100111 by a t c y a d laterally available by a proper change of cams-to form movable needle. various types of knotted tufts.

A further p p e i to in i w p thr d A further advantage is that our construction P ross ec sm and tuft y divertcan be attached to the present ordinary types of 30 ing mechanism Within a p W 100m 80 as to pile wire looms, including, for example, the comform tuft yarn knots in the place of the tuft manly known tapestry loom, without the expense y ps at pr n wov in fabrics by the Y of rebuilding the entire loom but creating a pile wire looms. wholly new loom in its capability of performing Afur h r p rp i t control the Positions of functions and weaving fabrics for which such 35 t yarns in a P Wile 100m by needles having looms were never previously suited.

yes r t e tuft yarns and having elongated A further advantage resides in the fact that openings below t e ey for Passage and Partial when our construction has been added to the control of stufier warp threads. pref bly pe ordinary type of loom as herein described, either 40 s the e ng t ,Openingsthe ordinary tapestry carpet fabrics, for example, 40

A further purpose is to closely guide the Warp or knotted fabrics, can be woven on the loom, by threads in a 'pile wire loom as by fixed reeds and merely disconnecting engaging. parts when it is laterally fixed uniformly spaced heddleeyes. desired to weave "the ordinary tapestry carpet or A further purpose is to take up slack in a conrug tinuous tuft Another feature is that the knotted fabrics A further purpose is to laterally divert Warp can be woven on the improved loom at approxithreads in a ile wire loom at points back of the lay reed dents, causing crossings to be effected in f the m rate of g f as P05 front of the lay reed dents and to manipulate slble on the ordlnary u 0 P f f ifi continuous tuft yarns, one for each pair, from a Furthel: P s W111 ppe r in the spec ca 50 point back of the lay reed dents so as to form the t n m h ap e ded c a ms. eyes and loops of knots 'infront of thelay reed dents Our mvenlflfin la not Only oihe methods either about the warp threads alone or about the or processes Involved but 130 me0hamSm bY Whlch warp threads and one or more weft threads, these methods or processes maybecarned out.

forming tuft yarn loops about pile wires, which To these and other ends, the invention con- 55 sists of certain parts and combinations of parts, all of which will be hereinafter described.

A practical embodiment of one type of mechanism among the various types by which the invention may be practiced is represented in the accompanying drawings forming a part of this specification, in which, similar characters ofreference indicate like parts in all views.

Figure 1 is a front elevation of the loom selected for our illustration.

Figure 2 is a left side elevation of the structure seen in Figure 1.

Figure 3 is a fragmentary enlarged right side elevation of the structure of Figure 1, showing more especially the driving mechanism.

Figure 4 is a fragmentary top plan view, taken from the position of line 44 of Figure 3, illustrating the pile wire mechanism. I

Figure 5 is a fragmentary sectional side elevation taken on line 5-5 of Figure 1, showing moreespecially the driving mechanism for the lay, shuttle and pile wire conveyer arm.

Figure 5a is a fragmentary section corresponding to part of Figure 5 but showing a modification of the tuft yarn guide.

Figure 5b is a fragmentary perspective view showing warp thread and tuft yarn relations in Figure 5.

Figure 6 is a fragmentary sectional side elevation, taken on line 6-6 of Figure 1, illustrating the heddle cam driving mechanism and a partial view of the fabric beam driving mechanism.

Figure 6a is a fragmentary perspective showing a tuft yarn-guide seen in Figure 6,

Figure 7 is an enlarged front elevation of a heddle, showing one preferred method of equal spacing of heddle wires.

Figure 8 is a sectional elevation, taken on line 88 of Figure 2, illustrating the needle cross bar mechanism.

Figure 9 is a fragmentary sectional top plan view taken on line 9-9 of Figure 2, illustrating the needle cross-bar mechanism and heddle arrangement.

Figure 10 is a fragmentary right side e1eva-.

of Figure 11, showing the needle cross-bar and 'guideways.

Figure 14 is a fragmentary sectional left side elevation, taken on line il -I4 of Figure 8, illustrating the cam operating mechanism for the up and down motion of the needle carrier frame.

Figure 15-is the same as Figure 14, except that the needle carrier frame operating cam for weavingthe true Sehna knot illustrated in Figures 33, 34, and 35, is shown in place of the one shown in Figure 14.

Figure 16 is a fragmentary sectional left side elevation, illustrating the front heddle operating cam, taken on line i6--i6 of Figure 8.

Figure 17 is a fragmentary sectional left side elevation, illustrating the rear heddle operating cam, taken on line "-41 of Figure 8'.

Figure 18 is an enlarged fragmentary sectional side elevation of the needle and chain warp heddle arrangement, taken on line l8--I8 of Figure 9, illustrating the fabric formation of the improved knotted tuft fabric as illustrated in Figure 30.

Figure 19 is an enlarged sectional side elevation of the needle and chain warp heddle arrangement, illustrating the first step from the position of the parts in Figure 18 in the formation of the knotted tuft fabric as shown in Figure 30.

Figures 20, 21, 22, 23, 24, and 25 are also enlarged sectional side elevations, illustrating the successive steps required for the forming of the knotted tuft fabric shown, in Figure 30.

Figures 18a, 19a, 20a, 21'a, 22a, 23a, 24a and 25a are top plan schematic views intended to illustrate the positions of a pair of chain warp threads, a stufler warp thread, a pile yarn thread and weft threads corresponding to the positions of the parts in Figures 18, 19, 20, 21, 22, 23, 24, and 25, respectively, to show the successive steps required for forming the knotted tufts.

Figures 18b, 19b, 20b, 21b, 22b, 23b, 23c, 24b, and 25b are fragmentary enlarged view of parts of Figures 18, 19, 20, 21, 22, 23, 24, and 25, respectively.

Figure 26 is an enlarged sectional side elevation of the needle and chain warp heddle arrangement illustrating the first step in the formation of the knotted tuft fabric shown in Figure 33. Figures 27, 28, and 29," are enlarged sectional side elevations, illustrating the successive steps' required for the formation of the knotted tuft fabric illustrated in Figure 33.

Figures 26a, 27a, 28a, and 290 are top plan schematic views intended to-iilustrate the posi-- tions of a pair-of chain warp threads, a strand of pile yarn thread and weft threads corresponding to the positlons'of the parts in Fig-' of the face of one fabric, illustrating the pile yarn and the knotted'tuft ends, both before and after pile wires have been withdrawn which have cut the knotted tuft loops and with all the threads shown as though loosely woven.

Figure 31 is a sectional elevation of the fabric illustrated in Figure 30,'also shown as though loosely woven.

Figure 32 is a sectional elevation, taken from the position of line 32-32 of Figure 30, i1lustrating the formation of the completed knotted tuft, both before and after being out, also shown as though loosely woven.

Figure 33 is a modification of an enlarged distorted plan view of the face of a knotted fabric, commonly known as the-Sehna knot, illustrating the pile yarn and the knotted tuft ends, both before and after pile wires have been withdrawn which have cut the knotted tuft loops and is similar to that illustrated in Figure 30, except that chain warp threads only appear, all of the threads shown as though loosely woven.

Figure 34 is a sectional elevation of the fabric illustrated in Figure 33, also shown as though loosely woven.

Figure 34a. is a cross section of a modification, similar to Figure 34.

Figure 35 is a sectional elevation, taken from the position of line 35-35 of Figure 33, illustrating the formation of completed knotted tufts,

both before and after being cut, also shown as though loosely woven.

Our invention is suitable for manufacture as a new loom unit and is in fact a new loom, but inasmuch as it uses features present in other looms we have found that new construction as a unit is not necessary but that the expense and delay of new loom manufacture can be avoided and the invention can be practiced in existing pile wire looms with comparatively little change in the existing looms.

Among the pile wire looms we have selected for the illustration a loom of the tapestry type, notwithstanding that other pile wire looms can be used, for the reason merely that the tapestry loom lends itself more readily to illustration of the invention than do other looms.

The preferred loom selected is mounted on a main frame 5!, on the rear of which are mounted in bearings the stufier warp beam 52 and the chain warp beam 53. On the uprights is mounted the pile yarn beam 54.

Our invention is suitable for use for fabric with or without stuffer warp threads and the preferred to illustrate the stuifer warp thread form first, with the understanding that where the additional stiffening and strengthening of the stuifer warp threads are not desired, these stuifer warp threads will merely be omitted without other change.

Assuming that stuffer warp threads are intended to be used, the unwinding of the stuifer warp threads from their beam is controlled by let-off mechanism common to pile wire looms, and therefore not shown in detail, which acts upon .the stufferwarp beam shaft 56.

As the stuffer warp threads 12 are unwound, they are engaged by a tension device 51 which need not be further described because it is of quite usual form. The threads next pass through lease rods 58, which also are of usual form, and are loosely attached to a tension device rod 59, extending from it forwardly under the guide bar 60, through the open extension portions 62a. and 630, between the wires of theheddles 62 and 63 and preferably through a special separating reed 64 and through an elongated tapered slot 82 in pile yarn needle 65, which latter are believed to be new. The stuifer warp threads- .then pass through the lay dents 61 of lay 68 let-ofi mechanism common to pile wire looms The unwinding of the pile yarn threads 13 from the pile yarn beam 54 is controlled through the beam shaft 540. by a friction brake 54b of a usual kind employed in pile wire looms and for this reason is not described in further detail.

The continuous pile yarn 13 is then passed through a tensioning device. 83 pivoted at 830. and whose pressure is applied by a weight 84 adjustable along the length of an arm 90. The tension device is pivoted in brackets BI and comprises a bell crank lever whose lower end 92 carries a tension bar 93 to take up any slack in the pile yarn l3 as-the latter is drawn from the pile yarn beam 54.

From the tension bar the pile or tuft yarn next passes about a roller 94 which is also supported by brackets 9|, and around a locating bar 95 which is capable of adjustment but which, when adjusted, is fixed.

The pile yarn 13 passes through the open extension portions 620. and 63a of the heddles 62' and 63, through the separating reed 64 and then through the eyes 8| of needles 66. These needles are capable of'movement and are moved not only horizontally, in a lateral direction, but upwardly and downwardly (preferably vertically). These motions are intermittent during the formation of the knots 88 and 89, as will hereafter more fully be described. The yarn next passes between the lay dents E'! of the lay 58 to the fell 59. t

For a complete cycle of operation as illustrated two upward and downward reciprocations of the needles take place, one upward movement. of the needles being through crossed warp threads and the other through parallel warp threads. Because of the alternation of thesheds the same warp thread is always up when the needle is moved upwardly between the crossed warp threads. The tension in this raised warp thread is increased by lifting it so that in its raised position it has sufiicient tension to protect against undue divergence of the warp thread by thepull of the tuft yarn.

The upper warp thread adjacent to the eye of its heddle can, therefore, safely be subjected to the pull of the tuft yarn and can be used as a guide for the tuft yarn. This is seen in Figure 5.

The construction of Figure 5 with the tuft yarn guided by the upper warp thread just below the heddle eye while quite satisfactory could be substituted'by a fixed tension bar at some appro- The two forms-of tension guide for the continf uous tuft yarn shown in Figures 5 and 5a are intended to be alternative.

When the lay B8 is back in its rearward position as indicated in Figure 5, the weft threads 15 and 16 are inserted. In the illustration this weft insertion is by means of a shuttle which may be of any usual or preferred kind and hence is not shown in elaborate detail. We recognize that any mechanism may beused which willinsert the weft threads and that the use of a shuttle is not essential.

The woven fabric 81 passes over the breastplate 96 and then around the spiked roll 91, whose shaft 98 is supported in bearings in the main frame 5|.

The several mechanisms of the loom are actuated in the proper sequence from a crankshaft 99, (Figure 3) extending transversely of the loom and journaled in suitable bearings in the main frame 5|. The crankshaft is operated in the 4- ace-7,449

usual manner by a manually controlled clutch mechanism, including a cone clutch pulley I00, connected by a belt with other machinery. The direction of rotation is indicated by the arrow.

5 The clutch mechanism includes a usual friction cone clutch, mounted to slide on and turn with pulley shaft sleeve IOI, (Figure 8).

- The pulley shaft sleeve IOI revolves on a stationary shaft I02, (Figure 8), secured at one end 10 in the main frame 5| and at the other end in the pulley bracket I03, (Figure 3). secured to a pinion I04, (Figure 8), in mesh with a gear 99a secured on the crankshaft 99.

The clutch member I05 (Figure 3), is shifted 15 by a lever I06 fulcrumed on the pulley bracket I03 and connected by a link I01 with an arm I08. The latter is secured on a rocker-shaft I09 which extends longitudinally of the loom and is journaled in the main frame 5|.

The forward end of the rocker-shaft I09 carries a hand lever IIO under the control of the weaver. This lever extends in a notched guideway III, (Figures 1 and 3), on the main frame The clutch is also provided with a friction brake which operates simultaneously with the clutch to stop the rotary motion of the pulley shaft from coasting after the friction clutch members I00 and I05 are disengaged.

When the hand lever I I0 is shifted, the oscilla- 30 tion of the rocker shaft I09 swings an arm II2 which is connected by link 3 with bell'crank lever 'II4. Lever |I4 operates brake band II5,

stopping or starting the loom.

A spring H5 is provided for holding the clutch in a non-acting or disengaged position.

The rotary motion of the crank-shaft 99, (Figure 8) is transmitted to a cam-shaft I I1, extend-.

this speed has been taken as half the speed of the crank-shaft.

The other end of the crank-shaft 99, (Figures 8 and 10), is provided with a pinion I20 secured 50 to the crank-shaft 99, so that when the crankshaft 99 is rotated a continuous but slower rotary motion is given to the cam sleeve I2 I mounted to rotate freely on the cam-shaft I I1. In the illustration this speed has been assumed to be onefourth of the speed of the crank-shaft.

It will therefore be apparent that the gear ratios of the pinion IIB secured to the crank-shaft 99 and the gear I I9 secured to the cam-shaft I I1 on the right side of the-loom, differ from the ratios 60 of the pinion I20 secured on crank-shaft 99 and the gear I22 secured to the cam sleeve I2I on the left side of the loom, (see Figure 8).

Therefore the picker cams I24 and I25 (Figures 5 and 6) make two revolutions for every one 65 revolution of the cam sleeve I2I. (Figures 8, 10,

and 10a), carrying the for actuating the various devices in the proper sequence, as hereinafter more fully described.

The heddles 02 and 63 are mounted to slide up 70 and down (Figures 8 and 9) in suitable guideways formed on the brackets I25 and I21 attached to and forming a part of the main frame 5|. The upper ends of the heddles 52 and 53 are hung on links I20 and I29 (Figures 5, 8, 16, and 17) connected to levers I30 and |3| secured The sleeve is a bracket 30'on the main frame 5|.

to transversely mounted rocker-shafts I32 and I33.

The shafts carry levers I34, |34a which are connected through links I35, I35a with levers I35 and I31 (Figures 16 and 17). These latter levers 5 are pivoted on the bracket I30 of the main frame 5| and carry at intermediate points along their lengths rollers I39 and I40. These rollers engage cam grooves in the cams HI and I42 which are mounted upon the cam sleeve I2I. The cam 10 sleeve rotates freely on the cam shaft H1 and is driven by pinion I20 through the gear I22.

When the loom is in operation the crank-shaft 99 is'rotated, carrying the pinion I20 in mesh with the gear I22 secured to the cam sleeve I2I. This rotates the cams HI and I42 in the direction shown by the arrow, and the cams IM and I42 impart an intermittent up and down motion" to the links I35 and I35a.

Each of the cams operates tointermittently lift and subsequently lower its own heddle and each of them lifts its heddle while the other heddle is being lowered and lowers its own heddle while the other heddle is being raised.

The links I35 and |35a actuate the heddles through levers I34 and |34a connected by the rocker shafts I32 and I33 with levers I and I3I, which in turn operate the heddles 'by links I28 and I29.

The heddle wires 52c and 630, (Figures '1, 8, 30 and 9) are secured to the heddleframes 02 and 63. It is important that they be equally spaced, thereby maintaining the chain warp threads 10 and 1| in proper alignment for the pile yarn needles 56 as herein more fully described. This novel construction allows free and unobstructed passage between the heddle wires in the open .extension portions 52a and 63a for the stufier warp threads 12 and the pile yarn 13, so that the up and down intermittent motion of the heddles 62 and 53 does not affect the relative positioning of the stuifer warp threads 12 and the pile yarn threads 13 in the shed.

The heddle wire eyes 62b and 63b are of a usual type, and when the heddles rise and fall, carry the chain warp threads and 1| with them, as will presently be described.

The separating reed 54 is secured to brackets I25 and I21 of the main frame 5|, (Figures 8 and 9). Its dents are also equally spaced and m serve also as separators for the several threads, namely a pair of chain warp threads 10 and 1|, a stufier warp thread 12 and a pile yarn thread 13, all included between each two' adjoining dents and all held in proper alignment for the 'corre- 55 sponding pile yarn needle 60. g l

The needle carrier frame I50 is mounted to slide up and down in suitable guideways formed on brackets I25 and I21 on the mainframe 5|,

(Figures 8 and 9) and is guided at the lower end I52, of the main frame 5|.

The outer end of the rocker-shaft I55 (Figures8 and 14) has secured to it a lever I55 connected by a link I51 with a lever I58 fulcrumed on The lever I50 carries a friction roller I59 engaging cam 

